Inlet system for an egr system

ABSTRACT

An embodiment of the present invention takes the form of a system that may recirculate a portion of the exhaust of at least one turbomachine where it may be mixed with the inlet air and re-enter the turbomachine without affecting reliability and availability of the unit. 
     An embodiment of the present invention provides an inlet system for an exhaust gas recirculation system. This inlet system may take a variety of forms and may optimize the direction that the portion of the recirculated exhaust stream flows within the inlet system.

This application is related to commonly-assigned U.S. patent applicationSer. No. 11/928,038 [GE Docket 227348], filed Oct. 30, 2007; U.S. patentapplication Ser. No. 11/953,524 [GE Docket 228179], filed Dec. 10, 2007;U.S. patent application Ser. No. 11/936,996 [GE Docket 228178], filedNov. 7, 2007; and U.S. patent application Ser. No. 11/960,198 [GE Docket229464], filed Dec. 19, 2007.

BACKGROUND OF THE INVENTION

The present invention relates to the exhaust gas emitted from aturbomachine, and more particularly to a system and method of utilizinga turbomachine as a prime mover of the exhaust gas recirculated withinan EGR system.

There is a growing concern over the long-term effects of Nitrogen Oxides(hereinafter NOx) and Carbon Dioxide (hereinafter “CO₂”) and SulfurOxides (SOx) emissions on the environment. The allowable levels ofemissions that may be emitted by a turbomachine, such as a gas turbine,are heavily regulated. Operators of turbomachines desire methods ofreducing the levels of NOx, CO₂, and SOx emitted.

Significant amounts of condensable vapors exist in the exhaust gasstream. These vapors usually contain a variety of constituents such aswater, acids, aldehydes, hydrocarbons, sulfur oxides, and chlorinecompounds. Left untreated, these constituents will accelerate corrosionand fouling of the internal components if allowed to enter theturbomachine.

Exhaust gas recirculation (EGR) generally involves recirculating aportion of the emitted exhaust stream through an inlet system of theturbomachine. The exhaust stream is then mixed with the incomingairstream prior to combustion. The EGR process facilitates the removaland sequestration of concentrated CO₂, and may also reduce the NOx andSOx emission levels. The recirculated exhaust mixes with the incomingairstream to create an inlet fluid. The exhaust stream should beadequately mixed with the airstream within a portion of the inletsection.

For the foregoing reasons, there is a need for an inlet system thatallows for integration with the EGR system. The inlet system shoulddirect the recirculated exhaust stream in a manner that allows formixing with the incoming airstream.

BRIEF DESCRIPTION OF THE INVENTION

In accordance with an embodiment of the present invention, a system forintroducing an exhaust stream into a turbomachine, the systemcomprising: an inlet system for channeling an inlet fluid towards acompressor section of a turbomachine, wherein the inlet fluid comprisesan airstream and an exhaust stream., an exhaust gas recirculation (EGR)system comprising at least one EGR skid and at least one EGR duct;wherein the at least one EGR duct is integrated with a portion of theinlet system; wherein the at least one EGR system is configured to:receive the exhaust stream at a first temperature from an exhaustsection of a turbomachine; wherein the exhaust stream comprisesconstituents at a first level; allows for the exhaust steam to enter theEGR skid, which reduces the constituents to a second level; and allowsfor the exhaust stream to exit the EGR skid at a second temperature andflow through the at least one EGR duct, wherein the exhaust streamsenters the inlet system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustrating an example of an EGR systemintegrated with a turbomachine.

FIG. 2 is a schematic illustrating an example of an inlet system for anEGR system, in accordance with a first embodiment of the presentinvention.

FIG. 3 is a schematic illustrating an example of an inlet system for anEGR system, in accordance with a second embodiment of the presentinvention.

FIG. 4 is a schematic illustrating an example of an inlet system for anEGR system, in accordance with a third embodiment of the presentinvention.

FIG. 5 is a schematic illustrating an example of an inlet system for anEGR system, in accordance with a fourth embodiment of the presentinvention.

FIG. 6 is a schematic illustrating an example of an inlet system for anEGR system, in accordance with a fifth embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description of preferred embodiments refers tothe accompanying drawings, which illustrate specific embodiments of theinvention. Other embodiments having different structures and operationsdo not depart from the scope of the present invention.

Certain terminology is used herein for the convenience of the readeronly and is not to be taken as a limitation on the scope of theinvention. For example, words such as “upper,” “lower,” “left,” “right,”“front”, “rear” “top”, “bottom”, “horizontal,” “vertical,” “upstream, ”“downstream,” “fore”, “aft”, and the like; merely describe theconfiguration shown in the Figures. Indeed, the element or elements ofan embodiment of the present invention may be oriented in any directionand the terminology, therefore, should be understood as encompassingsuch variations unless specified otherwise.

An embodiment of the present invention takes the form of a system thatmay recirculate a portion of the exhaust of at least one turbomachinewhere it may be mixed with the inlet air and re-enter the turbomachinewithout affecting reliability and availability of the unit. The elementsof the present invention may be fabricated of any material that canwithstand the operating environment under which the EGR system mayfunction and operate.

Generally, the exhaust gas recirculation system of an embodiment of thepresent invention comprises multiple elements. The configuration andsequence of the elements may be dictated by the composition of theexhaust gas. In general the steps comprising the exhaust gasre-circulation process are: cooling, scrubbing, de-misting, highefficiency particulate and droplet removal, and mixing. When the presentinvention is utilized, the diverted gas, blended with inlet air, can beintroduced to the turbine inlet without harm. As described below, thereare multiple arrangements that may be used to accomplish the exhaust gastreatment.

The present invention may be applied to the variety of turbomachinesthat produce a gaseous fluid, such as, but not limiting of, a heavy-dutygas turbine; an aero-derivative gas turbine; or the like. An embodimentof the present invention may be applied to either a single turbomachineor a plurality of turbomachines. An embodiment of the present inventionmay be applied to a turbomachine operating in a simple cycle or acombined cycle configuration.

As described below, an embodiment of the present invention may includeat least one EGR skid. The at least one EGR skid may utilize at leastone scrubber; or at least one scrubber and at least one downstream heatexchanger; or at least one scrubber and at least one upstream heatexchanger; or at least one scrubber, at least one downstream heatexchanger; and at least one upstream heat exchanger; or variouscombinations thereof. Moreover, the at least one EGR skid may alsoinclude an injector that may introduce a reagent for reducing the levelof harmful constituents within the exhaust stream; and a wetelectrostatic precipitator for removing the constituents.

Referring now to the Figures, where the various numbers represent likeelements throughout the several views, FIG. 1 is a schematicillustrating an example of an EGR system 100 integrated with aturbomachine 140. FIG. 1 illustrates a turbomachine 140 and an EGRsystem 100.

The turbomachine 140 generally comprises a compressor section 145, acombustion section 147, and a turbine section 150. An inlet section 160may be located upstream of the compressor section 145. The inlet sectionmay comprise at least one weather hood 165, an inlet duct 175, and aninlet plenum 180. An exhaust stack 155 may be located downstream of theturbine section 150.

The EGR system 100, comprises: an EGR skid 105; an EGR flow circulationdevice 100; an EGR inlet damper 115; and an EGR exhaust damper 120,which may be integrated with an turbine section 150 of the turbomachine140. The at least one EGR system 100 may be of a size and fabricated ofa material capable of withstanding the physical properties of theexhaust stream 125, such as, but not limiting of, a flowrate of about10,000 Lb/hr to about 50,000,000 Lb/hr and a temperature up to about1500 Degrees Fahrenheit. Here, the velocity of the exhaust stream 125may comprises a range of up to about 10,000,000 standard cubic feet perminute (SCFM).The inlet section 160 and the turbine section 150 maybound the flow path 130 of the EGR system 100.

The EGR skid 105 generally includes the component(s) of the EGR system100 that reduces the level of aforementioned constituents from theexhaust stream 125. These component(s) may include for example, but notlimiting of, at least one heat exchanger, at least one scrubber, atleast one demister, or similar components, (none of which areillustrated in the Figures). The EGR flow circulation device 110 maycirculate the exhaust during the operation of the EGR system 100.

Generally, during the operation of the EGR system 100, the EGR exhaustdamper 120 may open to allow for the exhaust stream 125 from the turbinesection 150 to enter the EGR system 100. The exhaust damper 120 mayapportion the total exhaust flow between a non-recirculated exhaust andthe exhaust stream 125. Then, the EGR skid 105 may reduce the level ofconstituents within the exhaust stream 125. Next, the EGR inlet damper115 may open to allow for the recirculated exhaust stream 125 to enterthe inlet section 160 of the turbomachine 140. The exhaust stream 125may then mix with the inlet air entering the inlet system 160 forming aninlet fluid 135. Throughout the figures the inlet air is represented byan arrow (s) located external to the at least one weather hood 165. Theinlet fluid 135 may then flow downstream to the compressor section 145of the turbomachine 140. During the aforementioned process, the EGR flowcirculation device 110 may move the exhaust stream 125 throughout theEGR system 100.

FIG. 2 is a schematic illustrating an example of an inlet system 160 foran EGR system 100, in accordance with a first embodiment of the presentinvention. FIG. 2 illustrates a turbomachine 140 and a first embodimentof the inlet system 160. Here, the inlet filter system 170 comprises afirst filter 220 and a second filter 225. The first filter 220 maybelocated upstream of the second filter 225. In an embodiment of thepresent invention, the first and second filters 220, 225 may be in theform of, for example, but not limiting of, a coalescing filter, or thelike.

In an embodiment of the present invention, the EGR system 100 comprisesat least one EGR duct 205, which serves to introduce the exhaust stream125 into the inlet system 160. The at least one EGR duct 205 maycomprise an inlet portion (not illustrated) integrated with the EGRsystem 100. The inlet portion may receive the exhaust stream 125 fromthe EGR inlet damper 115. The at least one EGR duct 205 may comprise anoutlet portion 209 integrated with the inlet system 160. The outletportion 209 may allow for the exhaust stream 125 to flow into the inletsystem 160. The at least one EGR duct 205 may be made into any shapethat allows for physical integration with a portion of the inlet system160. The at least one EGR duct 205 may be made of any material capableof withstanding the aforementioned operating environments and conditionsof the EGR system 100. For example, but not limiting of, the exhauststream 125 may flow a range of from about 300 feet/minute to about 5000feet/minute.

In the first embodiment of the present invention, the at least one EGRduct 205 may be integrated with the at least one weather hood 165. Forexample, but not limiting of, a Frame 6 turbomachine 140 may comprises asingle weather hood 165; whereas a Frame 9 turbomachine 140 maycomprises multiple weather hoods 165

The exhaust stream 125 may enter the inlet system 160 in a regionencompassed by the at least one weather hood 165, as illustrated in FIG.2. The outlet portion 209 of the at least one EGR duct 205 may beorientated on the at least one weather hood 165 to direct and distributethe exhaust stream 125 downstream towards the inlet filter system 170.The orientation of the outlet portion 209 may allow for a nearly eventemperature distribution when mixing with the airstream. The orientationof the outlet portion 209 may also reduce the possibility of obstructingthe airflow entering the at least one weather hood 165. The orientationof the outlet portion 209 may allow for the inlet fluid 135 to flowsymmetrically through the inlet filter system 170.

In an embodiment of the present invention, the orientation of an outletportion 209 may be determined by an angle X 210, illustrated as “X”; andan angle Y 215, illustrated as “Y”. Angle X 210 may determine theposition of a central section of the outlet portion 209 relevant toplane X, illustrated as “Px”. Angle Y 215 may determine the position ofa central portion of the exhaust stream 125 relative to plane Y,illustrated as “Py”. Also, the range of angle X 210 and angle Y 215 maybe optimized to account for an exit velocity of the exhaust stream 125.This may aid in the mixing of the exhaust stream 125 with the airstream.Furthermore, angle X 210 and angle Y 215 may aid in disturbing theexhaust stream 125 in a nearly uniform manner within the inlet system160. This distribution may reduce the chance of hotspots, or the like.

In an embodiment of the present invention, a user may optimize angle X210 and angle Y 215 with the goal of directing the maximum amount of theexhaust stream 125 downstream towards the inlet filter system 170. Here,the optimized value of angle Y 215 and may be dependent on the optimizedvalue of angle X 210, or vice-versa. For example, but not limiting of,angle X 210 may comprise a range of from about 0 degrees to about 90degrees; and angle Y 215 may comprise a range of from about 0 degrees toabout 45 degrees.

In use, the inlet system 160 of the first embodiment of the presentinvention may function as follows. The inlet system 160 may channel theairstream ingested by the compressor section 145 and mixes the exhauststream 125 to create the inlet fluid 135, as described. The airstreamusually comes from the environment in which the turbomachine 140operates. Initially, the airstream flows around the at least one weatherhood 165, which may prevent weather elements, such as rain, snow, etc,from entering the compressor section 145. The inlet fluid 135 may becreated in a region where the outlet portion 209 of the at least one EGRduct 205 is connected to the at least one weather hood 165, asdescribed. The inlet fluid 135 may then flow through an inlet filtersystem 170; which generally removes foreign objects and debris from theairstream. Next, the inlet fluid 135 may flow through a transition duct230, which may comprise a silencer section 235. Next the inlet fluid 135may flow through an inlet duct 175 and then an inlet plenum 180; thesecomponents may adjust the velocity and pressure of the airstream. Theinlet plenum 180 may connect the inlet system 160 with the turbomachine140 and allows for inlet fluid 135 to flow into the compressor section145.

The turbomachine 140 comprises a compressor section 145 having a rotor.The operation of the turbomachine 140 generally includes the following.The inlet fluid 135 deriving from the inlet system 160 enters thecompressor section 145, is compressed and then discharges to acombustion system 147, where a fuel, such as a natural gas, is burned toprovide high-energy combustion gases that drives the turbine section150. In the turbine section 150, the energy of the hot gases isconverted into work, some of which is used to drive the compressorsection 145.

FIGS. 3 through 6 illustrate alternate embodiments of the presentinvention. Tie discussion of each of these Figures focus on differencesbetween the discussed embodiment and the embodiment of FIG. 2

FIG. 3 is a schematic illustrating an example of an inlet system 160 foran EGR system 100, in accordance with a second embodiment of the presentinvention. Here, the inlet system 160 may be modified to include a thirdfilter 305. The third filter 305 may be located upstream of the at leastone EGR duct 205. The at least one EGR duct 205, in this secondembodiment may be located between the inlet filter system 170 and thethird filter 305.

The third filter 305 may absorb a portion of the debris and foreignobjects within the airstream entering the inlet system 160. The thirdfilter 305 may reduce the likelihood of the exhaust stream 125 enteringthe inlet system 160 flowing out of the at least one weather hood 165 tothe ambient environment of the turbomachine 140. The third filter 305,may aid in containing the exhaust stream 125 during a shutdown of theturbomachine 140. In an embodiment of the present invention, the thirdfilter 305 may be in the form of, for example, but not limiting of, acoalescing filter, or the like.

FIG. 4 is a schematic illustrating an example of an inlet system 160 foran EGR system 100, in accordance with a third embodiment of the presentinvention. Here, the inlet system 160 may be modified to locate theoutlet portion 209 of the at least one EGR duct 205 between the firstfilter 220 and the second filter 225. In this third embodiment of thepresent invention, the outlet portion 209 may be orientated to allow theexhaust stream 125 to be introduced into the inlet system 160 betweenthe first filter 220 and the second filter 225.

This third embodiment of the present invention may reduce the likelihoodof the exhaust stream 125 entering the inlet system 160 flowing out ofthe at least one weather hood 165 to the ambient environment of theturbomachine 140. The third embodiment may comprise multiple EGR ducts205, which may distribute the exhaust stream 125 around a periphery ofthe inlet filter system 170. Here, the EGR ducts 205 may be positionedbetween the first filter 220 and the second filter 225. Alternatively,the at least one EGR duct 205 may be located at a top, bottom, orcentral location of the inlet filter system 170. This may aid withdistributing the exhaust stream 125 in a nearly uniform manner.

FIG. 5 is a schematic illustrating an example of an inlet system 160 foran EGR system 100, in accordance with a fourth embodiment of the presentinvention. Here, the inlet system 160 may be modified to locate theoutlet portion 209 of the at least one EGR duct 205 between inlet filtersystem 170 and the silencer section 235 of the transition duct 230.

The configuration of the fourth embodiment may reduce the likelihood ofexhaust stream 125 flowing upstream and out of the at least one weatherhood 165. The present fourth embodiment may allow for a reduction in therequired supply pressure of the exhaust stream 125 exiting the at leastone EGR duct 205. The present fourth embodiment may allow for areduction in inlet equipment size located upstream of the at least oneEGR duct 209.

FIG. 6 is a schematic illustrating an example of an inlet system 160 foran EGR system 100, in accordance with a fifth embodiment of the presentinvention. Here, the inlet system 160 may be modified to locate theoutlet portion 209 of the at least one EGR duct 205 downstream of thesilencer section 235. This may reduce the likelihood of flow distortionsdeveloping when the exhaust stream 125 and the airstream are mixed tocreate the inlet fluid 135.

As illustrated in FIG. 6, this fifth embodiment of the present inventionmay locate the outlet portion 209 of the at least one EGR duct 205 onvarious locations of the inlet duct 175 or the inlet plenum 180. Forexample, but not limiting of, these locations may be adjacent to adownstream location of the silencer section 235, illustrated as an “A”;and/or adjacent to a downstream end of the inlet plenum 180, illustratedas a “B” or “C”.

In an embodiment of the present invention, locations A, B, and C mayrepresent a location for one at least one EGR duct 205. In an alternateembodiment of the present invention, locations A, B, and C may representpositions where multiple EGR ducts 205 are integrated on the inletsystem 160. For example, but not limiting of, a first EGR duct 205 maybe positioned at location A; a second EGR duct 205 may be positioned atlocation B; and a third EGR duct 205 may be positioned at location C.

The locations of A, B, and C may depend on the compressor inlet flowfield characteristics of which the inlet fluid 135. An embodiment of thepresent invention seeks to distribute the inlet fluid 135 in a nearlyuniform manner at the entrance of the compressor section 145. Here,multiple distribution points of the inlet fluid 135 may be required tocounteract flow distortions created by other flow obstructions and flowturning in the inlet system. One well-known source of flow distortion isa plenum center-body 306. Injection of exhaust stream flow 125 throughwalls of the center-body 306, especially toward the bottom of the plenumis one non-limiting embodiment of the present invention

The fifth embodiment of the present invention may allow for a reductionin the size of some of the inlet system 160 components. Here, the inletsystem 160 may be sized for the airstream flow minus the exhaust stream125 flow, which is introduced downstream of the silencer section 235.Moreover, the pressure drop of a position of the inlet system 160upstream of the silencer section 235 may be reduced when the exhauststream 125 is downstream of the silencer section 235.

FIG. 6 also illustrates an alternate embodiment of at least one EGR duct205. Here, the at least one EGR duct 205 comprises a plurality of vanes207 for directing the flow of the exhaust stream 125. This may assist increating the inlet fluid 135. In another alternate embodiment of thepresent invention, the at least one EGR duct 205 may comprise aplurality of movable vanes 207. Here, a user may adjust the position ofthe movable vanes 207 to an optimized angle for directing the path ofthe exhaust stream 125. Although, these embodiments of the at least oneEGR duct 205 are introduced in FIG. 6, the applicability is not limitedto FIG. 6. These embodiments of the at least one EGR duct 205 may beapplied to any of the discussed or related embodiments of the inletsystem 160 of the present invention.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof.

Although specific embodiments have been illustrated and describedherein, it should be appreciated that any arrangement, which iscalculated to achieve the same purpose, may be substituted for thespecific embodiments shown and that the invention has other applicationsin other environments. This application is intended to cover anyadaptations or variations of the present invention. The following claimsare in no way intended to limit the scope of the invention to thespecific embodiments described herein.

1. A system for introducing an exhaust stream into a turbomachine, thesystem comprising: an inlet system for channeling an inlet fluid towardsa compressor section of a turbomachine, wherein the inlet fluidcomprises an airstream and an exhaust stream, an exhaust gasrecirculation (EGR) system comprising at least one EGR skid and at leastone EGR duct; wherein the at least one EGR duct is integrated with aportion of the inlet system; wherein the at least one EGR system isconfigured to: receive the exhaust stream at a first temperature from anexhaust section of a turbomachine; wherein the exhaust stream comprisesconstituents at a first level; allows for the exhaust steam to enter theEGR skid, which reduces the constituents to a second level; and allowsfor the exhaust stream to exit the EGR skid at a second temperature andflow through the at least one EGR duct, wherein the exhaust streamsenters the inlet system.
 2. The system of claim 1, wherein the inletsystem comprises at least one of the following: at least one weatherhood configured to reduce an amount of precipitation entering the inletsystem, wherein the at least one weather hood comprises an opening forreceiving the airstream; and an inlet filter system configured to reducean amount of foreign objects entering the compressor section.
 3. Thesystem of claim 2, wherein the at least one EGR duct is integrated witha portion of the weather hood.
 4. The system of claim 3, wherein anorientation of an outlet portion of the at least one EGR duct isdetermined by an angle X and an angle Y.
 5. The system of claim 4,wherein the angle X comprises a range of from about 0 degrees to about90 degrees.
 6. The system of claim 5, wherein the angle Y comprises arange of from about 0 degrees to about 45 degrees.
 7. The system ofclaim 6, wherein the opening of the at least one weather hood is coveredby at least one filter; wherein the at least one filter reduces a levelof debris within the airstream entering the inlet section.
 8. The systemof claim 2, wherein the inlet filter system comprises a first filter anda second filter, wherein the first and second filters are locateddownstream of the weather hood.
 9. The system of claim 8, wherein the atleast one EGR duct is located between the first filter and the secondfilter, and is configured to allow the exhaust stream to flow betweenthe first filter and the second filter.
 10. The system of claim 2,wherein the inlet system comprises a transition duct, wherein thetransition duct comprises a silencer section.
 11. The system of claim10, wherein the at least one EGR duct is located downstream of the firstfilter and the second filter and upstream of the silencer section and isconfigured to allow the exhaust stream to flow downstream of the firstfilter and the second filter.
 12. The system of claim 2, wherein theinlet system further comprises an inlet duct located downstream of thetransition duct and upstream of an inlet plenum, wherein the inletplenum is connected to an upstream portion of the compressor section.13. The system of claim 12, wherein the at least one EGR duct is locatedon a portion of the inlet duct adjacent to the transition duct.
 14. Thesystem of claim 12, wherein the at least one EGR duct is located on aportion of the inlet plenum located adjacent the compressor section. 15.The system of claim 1, wherein the at least one EGR duct comprises aplurality of vanes for directing a flow path of the exhaust stream. 16.The system of claim 15, wherein the plurality of vanes are movable tochange the direction of the flow path of the exhaust stream.
 17. Thesystem of claim 1, wherein the at least one EGR duct nearly uniformlydistributes the inlet fluid within the inlet system.